Automatic treadmill walking belt tensioning and alignment system

ABSTRACT

An automatic treadmill walking belt tensioning and alignment system can automatically maintain one or both of a treadmill walking belt&#39;s alignment and tension. The system can include force sensors that sense the tension of a treadmill walking belt about a treadmill roller by sensing a force applied to adjustment actuators positioned on opposite sides of the treadmill roller. The position of the roller can be adjusted to adjusted to ensure proper tension and alignment of the treadmill walking belt. Position sensors may be deployed on opposite sides of the walking belt to detect when the walking belt is off-center, signaling the adjustment actuators to operate to return the walking belt to its centered position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. provisional patent application No. 62/232,938, filed Sep. 25, 2015, the contents of which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

One or more embodiments of the invention relates generally to exercise devices. More particularly, embodiments of the present invention relate to a treadmill walking belt tensioning and alignment system that can automatically maintain proper belt tensioning and alignment for treadmill belts.

2. Description of Prior Art and Related Information

The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.

Treadmills frequently require adjustment of the tensioning of the treadmill walking belts and alignment of the walking belt. Treadmill walking belts can get out of alignment due to normal wear and tear, improper maintenance and uneven gait pattern of the user. Neglecting to maintain proper tensioning and alignment of the treadmill walking belts frequently necessitates maintenance or replacement of the treadmill walking belts.

Currently, adjustment of the tension and alignment of treadmill walking belts is performed manually. A user typically has to find an adjustment mechanism, turn the mechanism with a hand tool, and check the resulting tension and alignment. This process is typically repeated until the proper tension and alignment is achieved. For home treadmill systems, this required maintenance is often overlooked, typically resulting in the premature failure of the treadmill and/or treadmill walking belt.

In view of the foregoing, there is a need for a method and apparatus for automatically maintaining proper treadmill walking belt alignment and tension.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide an automatic treadmill walking belt adjustment system comprising adjustment actuators operable apply a force to a treadmill roller about which a treadmill walking belt revolves; a force sensor sensing a tension in the treadmill walking belt by measuring the force applied by the adjustment actuators; and a controller operable to control the force applied by the adjustment actuators, thereby maintaining proper tension in the treadmill walking belt.

Embodiments of the present invention further provide an automatic treadmill walking belt adjustment system comprising adjustment actuators operable apply a force to treadmill roller about which a treadmill walking belt revolves; a force sensor sensing a tension in the treadmill walking belt by measuring the force applied by the adjustment actuators; a position sensor operable to detect a side-to-side position of the treadmill walking belt; and a controller operable to control the force applied by the adjustment actuators, thereby maintaining proper tension in the treadmill walking belt and maintaining proper side-to-side alignment of the treadmill walking belt.

Embodiments of the present invention also provide an automatic treadmill walking belt adjustment system comprising electronic adjustment actuators operable apply a force to opposite sides of a treadmill roller about which a treadmill walking belt revolves; a force sensor sensing a tension in the treadmill walking belt by measuring the force applied by the adjustment actuators; and a position sensor operable to detect a side-to-side position of the treadmill walking belt.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the present invention are illustrated as an example and are not limited by the figures of the accompanying drawings, in which like references may indicate similar elements.

FIG. 1 is a side perspective view of a treadmill operable with the automatic treadmill walking belt tension and alignment system according to an exemplary embodiment of the present invention;

FIG. 2 is a schematic representation of an automatic treadmill walking belt tension system according to an exemplary pneumatic or hydraulic embodiment of the present invention;

FIG. 3A is a schematic representation of an automatic treadmill walking belt alignment system usable with the automatic treadmill walking belt tension system of FIG. 2;

FIG. 3B is a schematic representation of an automatic treadmill walking belt alignment and tension system usable with the automatic treadmill walking belt tension system of FIG. 2, illustrating automatic adjustment of the drive roller;

FIG. 3C is a schematic representation of an automatic treadmill walking belt alignment and tension system, illustrating automatic adjustment of the tension roller along with optional manual adjustment;

FIG. 3D is a schematic representation of an automatic treadmill walking belt alignment system usable with the automatic treadmill walking belt tension system of FIG. 2, illustrating a concave longitudinal drive (or tension, or both) roller design according to an exemplary embodiment of the present invention;

FIG. 4 is a schematic diagram illustrating sensing and operation of the valves of the automatic treadmill walking belt tension and alignment system according to an exemplary pneumatic or hydraulic embodiment of the present invention;

FIG. 5 is an exemplary schematic wiring diagram for a treadmill operable with an electric automatic treadmill walking belt tension and alignment system; and

FIG. 6 is an exemplary schematic diagram illustrating treadmill controls.

Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.

The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE OF INVENTION

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

The present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated by the figures or description below.

Devices or system modules that are in at least general communication with each other need not be in continuous communication with each other, unless expressly specified otherwise. In addition, devices or system modules that are in at least general communication with each other may communicate directly or indirectly through one or more intermediaries.

A description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present invention.

As is well known to those skilled in the art, many careful considerations and compromises typically must be made when designing for the optimal configuration of a commercial implementation of any system, and in particular, the embodiments of the present invention. A commercial implementation in accordance with the spirit and teachings of the present invention may be configured according to the needs of the particular application, whereby any aspect(s), feature(s), function(s), result(s), component(s), approach(es), or step(s) of the teachings related to any described embodiment of the present invention may be suitably omitted, included, adapted, mixed and matched, or improved and/or optimized by those skilled in the art, using their average skills and known techniques, to achieve the desired implementation that addresses the needs of the particular application.

Broadly, embodiments of the present invention provide an automatic treadmill walking belt tensioning and alignment system that can automatically maintain one or both of a treadmill walking belt alignment and tension. The system can include pressure switches, operable by air or hydraulics, or the system could be an electronic system. In either embodiment, the system senses the force applied to a treadmill roller, such as the drive roller or the tension roller, due to the tension of a treadmill walking belt, via a separate force sensor or via adjustment actuators positioned at ends of the roller. In the pneumatic embodiment, a three-position solenoid valve can allow air from an accumulator to flow into the adjustment actuators, or allow air to flow out of the adjustment actuators, as needed, to maintain proper tension on the walking belt of the treadmill. In the electric version, a predetermined force in the force sensors is maintained by adjusting the adjustment actuators against the roller. Position sensors may be deployed on opposite sides of the treadmill walking belt to detect when the walking belt is off-center, signaling the adjustment actuators to operate to return the walking belt to its centered position.

Referring now to FIGS. 1 through 3C, a treadmill 10 can include one or more treadmill walking belts 12 (also referred to as walking belts 12) that run in a loop between rollers 14 on each end thereof. Typically, one of the rollers 14 is a drive roller and one of the rollers is a tension roller. Ends 16 of the roller 14 may be supported in various manners that permit movement of the roller 14 by one or both adjustment actuators 18 in a direction shown by arrow 20.

Referring to FIG. 1, the treadmill 10 can further include a display system 5 that can include a display 7, such as a tablet computer, or the like, positioned at the front of the treadmill 10. The display system 5 can further include a camera 9. The display system may be useful for watching a user's feet for gait, for brain interaction assessments before and after an exercise, and for providing safety sensors for foot and body positioning, for example. The display system 5 may also interact with the user in other manners, such as providing information or entertainment to the user during an exercise.

Referring back to FIGS. 3A through 3C, an adjustment actuator 18 will be present on both ends 16 of the roller 14, as shown. However, in some embodiments, only one adjustment actuator 18 may be used, with the opposite end fixed, albeit, in this embodiment, only alignment may be achieved without a tension adjustment.

Typically, the adjustment actuators 18 will be present on both ends 16 of one of the roller 14. However, in some embodiments, adjustment actuators 18 will be present on both forward and rearward rollers (drive and tension rollers, at both ends of the loop of the walking belt 12). In some embodiments, one of the rollers is a drive roller, as shown in FIG. 3B, driven by a drive motor 11. The opposite roller may be a tension roller 14B, where manual adjustment screws 18A may be used to adjust the tension roller 14B. Of course, an additional set of adjustment actuators 18 may be used to adjust the tension roller 14B. Alternatively, as shown in FIG. 3C, the drive roller 14 may be fixed while the tension roller 14B may be adjusted by either or both of adjustment actuators 18 and/or manual adjustment screws 18A. Thus, for a typical single-belt treadmill 10, there may be as few as one adjustment actuator 18 to as many as four adjustment actuators 18, typically two adjustment actuators 18 are used.

Still referring to FIGS. 3A through 3C, position sensors 22 may be disposed on opposite sides of the walking belt 12, at any location along its length. While one position sensor 22 is shown on each side of the walking belt 12 in FIG. 3A, multiple positions sensors 22 may be disposed on each side of the walking belt 12, or only one position sensor 22 may be present only on one side of the walking belt 12. The position sensor 22 may be of various configurations. In some embodiments, a mechanical sensor may detect contact with the walking belt 12. In other embodiments, an optical sensor 22A may be used to detect position of the walking belt 12. Such optical sensors may detect the actual position of the walking belt 12, or may be used detect a line painted on the inside surface of the treadmill walking belt 12, where, when the line is visible, the walking belt 12 is off-center, for example. Regardless of the type of sensor, the position sensor 22 may be any such sensor that can detect side-to-side movement of the walking belt 12 (movement shown by arrow 24).

Referring specifically to FIG. 2, in a pneumatic embodiment, a motor 30 may be used to drive an air compressor 32 that can receive ambient air via an air filter 34, for example. Air may be delivered from the air compressor 32 to an accumulator 36 through a check valve 38. Once a predetermined air pressure is reached, an air pressure switch 40 may turn off the motor 30.

Air from the accumulator 36 may be delivered via another check valve 42 to a three-position solenoid air valve 44. An air pressure switch 46 can sense the treadmill walking belt tension by sensing the air pressure in the adjustment actuators 18. The three-position solenoid air valve 44 allows the air from the accumulator 36 to flow into the adjustment actuators 18, thereby increasing the force produced by the adjustment actuators 18, thus increasing the tension of the treadmill walking belt 12. Conversely, when the treadmill walking belt tension is excessive, air pressure switches 46 activate the three-position solenoid air valve 44 to discharge air from the adjustment actuators 18.

Referring back to FIG. 3A, when one of the position sensors 22 detects that the treadmill walking belt 12 has run away from its normal centerline position, then proper adjustment of the adjustment actuators 18 may be performed to move the walking belt 12 back to its proper position. For example, the position sensor 22 on the left side activates the left-side three-position solenoid air valve 44 to increase the air pressure in the adjustment actuator 18 on the left side, forcing the treadmill walking belt 12 back to its centerline position. The same action takes place when the treadmill walking belt 12 runs right of the centerline position.

In some embodiments, as shown in FIG. 3D, to help maintain alignment, the roller 14 may be replaced by a concave roller 14B, where a center portion 14-1 has a smaller diameter than an end portion 14-2 of the roller 14B. Such a design helps maintain the walking belt 12 in alignment. The roller design of FIG. 3B may be used with or without the position sensors 22.

In some embodiments, the treadmill walking belt tension may be maintained by inserting spring(s) of appropriate tension between the roller 14 and the frame of the treadmill 10. Thus, the elongation of the treadmill walking belt 12 with time and use will not affect the treadmill walking belt tension because the springs can very closely maintain the desired tension.

Referring now to FIG. 4, a logic diagram 60 shows the various logic performed by a pneumatic system according to an exemplary embodiment of the present invention to control the motor 30, the valves 44, and the like. The logic may be performed by a processor 62 that is programmed to perform the logic shown in the logic diagram 60. The logic diagram 60 shows how the various inputs, such as those from the adjustment actuators 18, air pressure switch 40, air pressure switches 46, and position sensors 22, control the outputs of the three-position air solenoid valves 44.

FIGS. 5 and 6 show electrical schematics that may be used in the treadmill 10 of the present invention in an electric version, where the air compressor motor, accumulator, and like pneumatic components are not required. In this embodiment, the adjustment actuators 18 may be electronic components that can sense a force that the roller 14, 14A applies to the adjustment actuators 18 due to tension in the walking belt 12 and actuate linearly to adjust the force appropriately to maintain proper tension and alignment of the walking belt 12. The electronic configuration may be utilized in the systems shown in FIGS. 3A through 3C, for example.

It should be noted that some treadmills are designed to operate in both the forward and reverse directions to provide the appropriate exercise to a user. Embodiments of the present invention are operable on such treadmills, regardless of operation direction, to maintain proper walking belt tension and alignment.

While the above discussion uses an air compressor, air-based adjustment actuators and air pressure switches, the air system can be replaced with other systems, including an all-electric system or a hydraulic system, for example. Thus, with the hydraulic system, the air compressor may be replaced with a hydraulic fluid pump and the accumulator may be replaced with a hydraulic fluid reservoir, for example. With an electric system, the pressure switches can be replaced with a force sensor and the adjustment actuators may be electronic linear actuators, for example.

While a treadmill 10 having a single walking belt 12 is shown in FIG. 1, the system of the present invention may be used for various devices having walking belts. For example, treadmill-stepper exercise systems use two separate walking belts, one for each of the user's legs, for allowing a stepping action while the walking belt moves to create a treadmill action. Embodiments of the present invention may be used in such treadmill-steppers in a similar fashion, where two separate systems may be employed to monitor the tension and alignment of each of the two treadmill walking belts.

The system described above may be retrofitted into existing treadmills or may be integrated into the treadmill during its manufacture.

All the features disclosed in this specification, including any accompanying abstract and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

Claim elements and steps herein may have been numbered and/or lettered solely as an aid in readability and understanding. Any such numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims.

Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements.

The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species.

The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.

Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.

The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention. 

What is claimed is:
 1. An automatic treadmill walking belt adjustment system comprising: adjustment actuators operable to automatically adjust a force applied by a treadmill walking belt onto a treadmill roller by adjusting a position of the treadmill roller.
 2. The automatic treadmill walking belt adjustment system of claim 1, further comprising: a force sensor sensing a tension in the treadmill walking belt by measuring the force applied by the adjustment actuators to the treadmill roller; and a controller operable to control the force applied by the adjustment actuators, thereby maintaining proper tension in the treadmill walking belt.
 3. The automatic treadmill walking belt adjustment system of claim 2, wherein the force sensor is integral with the adjustment actuator.
 4. The automatic treadmill walking belt adjustment system of claim 2, wherein the adjustment actuators are air adjustment actuators and the force sensor is an air pressure switch.
 5. The automatic treadmill walking belt adjustment system of claim 4, further comprising an accumulator maintaining a predetermined fluid pressure therein, the accumulator operably connected to the adjustment actuators to deliver fluid to the adjustment actuators when an increase in the force is required to maintain tension or maintain alignment of the treadmill belt.
 6. The automatic treadmill walking belt adjustment system of claim 5, further comprising a three-way solenoid operable to deliver fluid from the accumulator to the adjustment actuators or to remove fluid from the adjustment actuators.
 7. The automatic treadmill walking belt adjustment system of claim 1, further comprising a position sensor operable to detect a side-to-side position of the treadmill walking belt, wherein the adjustment actuators position the treadmill roller to maintain a central side-to-side positioning of the treadmill walking belt.
 8. The automatic treadmill walking belt adjustment system of claim 7, wherein the position sensors are optical sensors.
 9. The automatic treadmill walking belt adjustment system of claim 7, wherein the position sensors are mechanical sensors.
 10. The automatic treadmill walking belt adjustment system of claim 1, wherein the adjustment actuators are electronic.
 11. The automatic treadmill walking belt adjustment system of claim 1, wherein one of the adjustment actuators are each disposed on opposite sides of the treadmill roller.
 12. The automatic treadmill walking belt adjustment system of claim 11, wherein the treadmill roller is a drive roller.
 13. The automatic treadmill walking belt adjustment system of claim 11, wherein the treadmill roller is a tension roller.
 14. An automatic treadmill walking belt adjustment system comprising: adjustment actuators operable apply a force to treadmill roller about which a treadmill walking belt revolves; a force sensor sensing a tension in the treadmill walking belt by measuring the force applied by the adjustment actuators; a controller operable to control the force applied by the adjustment actuators, thereby maintaining proper tension in the treadmill walking belt and maintaining proper side-to-side alignment of the treadmill walking belt.
 15. The automatic treadmill walking belt adjustment system of claim 14, further comprising a position sensor operable to detect a side-to-side position of the treadmill belt.
 16. The automatic treadmill walking belt adjustment system of claim 15, wherein the position sensors are optical sensors.
 17. The automatic treadmill walking belt adjustment system of claim 15, wherein the position sensors are mechanical sensors.
 18. The automatic treadmill walking belt adjustment system of claim 15, wherein the electronic adjustment actuator and the force sensor are integral.
 19. An automatic treadmill walking belt adjustment system comprising: electronic adjustment actuators operable apply a force to opposite sides of a treadmill roller about which a treadmill walking belt revolves; a force sensor sensing a tension in the treadmill walking belt by measuring the force applied by the adjustment actuators; and a position sensor operable to detect a side-to-side position of the treadmill walking belt.
 20. The automatic treadmill walking belt adjustment system of claim 19, wherein the electronic adjustment actuator and the force sensor are integral. 